Durable polymeric panels and devices exhibiting antiballistic capacity made therefrom

ABSTRACT

A polymeric coating composition for use in overlaying at least a portion of a substrate element composed of a plural component polymeric system composed of a reactive blend of at least one first component and at least one second component, wherein the first component consists essentially of a polymer and/or blend of polymers present in an amount sufficient to impart a predetermined amount of tensile strength, hardness, flexibility and adhesive strength to the resulting polymeric coating, and the second component is an isocyanate or isocyanate quasi-prepolymer. The substrate element is a blast-resistant polymeric material having low surface energy and/or low reactivity at or near the surface of the substrate. Also disclosed is a blast and/or ballistic-resistant construction element composed of a structure having the aforementioned polymeric material thereover. The polymeric material has a substrate matrix containing at least one of ultrahigh molecular weight polyethylene, aramid materials, and the like.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. patent application Ser. No.12/797,447 filed Jun. 9, 2010 which is a Continuation in part ofInternational Application No. PCT/US2009/067478 filed Dec. 10, 2009,claims the benefit of U.S. Provisional Application No. 61/174,845 filedMay 1, 2009 and U.S. Provisional Application No. 61/122,305 filed Dec.12, 2008, all of which are incorporated herein by reference in theirentireties.

BACKGROUND

The present invention relates to a polymeric composition suitable foruse in a variety of coating applications for use with friable or easilydamaged substrate materials and/or materials having poor adhesioncharacteristics. More particularly, the composition disclosed hereinrelates to materials that can be used to coat blast resistant and/orshrapnel resistant panels and the like. The present invention alsorelates to durable polymeric panels coated with the polymeric coatingand exhibiting enhanced wear resistance as well as antiballistic and/orblast resistant characteristics as well as devices employing the same.

Various polymeric materials have been proposed for use in a variety ofuseful objects including, but not limited to, producing blast and/orshrapnel-resistant structures and components. Materials such as ultrahigh molecular weight polyethylene (UHMWPE) based materials availableunder trade names such as DYNEEMA and SPECTRA, aramid materials such asKEVLAR and TWARON as well as polymeric matrixes that arefiber-reinforced with fiber materials including fibers formed from oneor more of the aforementioned polymers and have been found to exhibitballistic damping characteristics.

While exhibiting favorable physical and performance characteristics,including but not limited to high strength-to-weight ratios, hightensile and high impact resistance and resistance to shock loading,these materials are not without drawbacks and challenges. Among theseare susceptibility to friability and surface chipping and flaking. It isalso difficult to provide a durable, long lasting aesthetic orprotective coated surface to such materials. Thus their usefulness invarious applications is quite limited.

These drawbacks are particularly noteworthy in applications such as theproduction of blast and shrapnel armor for location in various wear andtraffic regions for example in the floors and wall regions of aircraftand various motorized vehicles. Panels and other constructs formed froma suitable armor material such as DYNEEMA or SPECTRA are attached to theassociated vehicle structure to provide protection to the occupants.While these panels impart elevated armored protection, the materials aresusceptible to wear such as gouging, chipping and flaking as devicessuch as cargo and/or ordinance-related items are dragged or dropped onpanel surfaces during routine use and operation. Additionally, panelsurfaces made of such materials are difficult to paint or coat for tolower adhesion characteristics inherent in the polymeric materialscomposing the panels. In situations where the panels are exposed toelevated levels of foot traffic or heavy traffic with equipment orvehicle loading, it can be desirable to provide armor panels thatprovide even greater levels of durability and wear resistance.

Thus it would be desirable to provide a coating composition that couldbe employed to coat at least a portion of a surface a friable substratematerial. It is also desirable to provide a coating composition that canbe employed to encased a suitable substrate material and adhere thereto.It would also be desirable to provide a coating composition that canadhere effectively to a substrate having challenging adhesioncharacteristics. It would be desirable to provide a coating compositionthat could be employed with an associated armor panel or panels withoutunduly compromising the ballistic or resistance or blast resistance ofthe panel or other such structural component. It would also be desirableto provide a panel having antiballistic and/or blast resistantcharacteristics as well as enhanced wear resistance suitable for use ina device or vehicle. Finally, it would be desirable to provide a deviceor vehicle component with these characteristics and an associatedvehicle having at least one armor panel.

SUMMARY

Disclosed herein is a polymeric coating composition for use inoverlaying at least a portion of a substrate element, the composition isa plural component polymeric system suitable for spray application to asuitable substrate. The plural component system is composed of areactive blend of at least one first component and at least one secondcomponent, wherein the first component consists essentially of a polymerand/or a blend of polymers present in an amount sufficient to impart apredetermined amount of tensile strength, hardness, flexibility andadhesive strength to the resulting polymeric coating and the secondcomponent is an isocyanate or isocyanate quasi-prepolymer. The substrateelement can be composed, at least in part, of a blast-resistantpolymeric material. The polymeric coating composition can be applied tovarious substrate materials having low surface energy and/or lowreactivity at or near the surface of the substrate.

Also disclosed is a blast and/or ballistic-resistant constructionelement composed of a structure having the aforementioned polymericmaterial in overlying attached relationship thereto. The polymericmaterial of the structure has a substrate matrix containing at least oneof ultrahigh molecular weight polyethylene, aramid materials, and thelike.

DESCRIPTION OF THE DRAWING

The description herein makes reference to the accompanying drawings inwhich like reference numerals refer to like parts throughout the severalviews and wherein:

FIG. 1 is a perspective view of a panel according to an embodimentdisclosed herein;

FIG. 2 is an expanded cross sectional view taken along the 2-2 line ofFIG. 1;

FIG. 3 is a detail view of FIG. 1;

FIG. 4 is a partial cross section of an alternate embodiment of thearmor panel device as disclosed herein;

FIG. 5 is a partial cross section of an alternate embodiment of thepanel cap member as disclosed herein with two substrate panel members injoined relationship thereto;

FIG. 6 is a detail view of a corner configuration for a panel cap memberas disclosed herein;

FIG. 7A is an alternate embodiment of a panel with apertures presenttherein; and

FIGS. 7B-C are a detail view of an embodiment of threaded armor insertemployed with the armor panel disclosed herein.

DETAILED DESCRIPTION

Disclosed herein is a novel composition that can be employedadvantageously as a coating composition on substrates that heretoforehave been considered difficult to coat due to characteristics of theassociated substrate material, including but not limited to, low surfaceenergy and/or low reactivity of the polymeric material at or near thesurface of the substrate.

Also disclosed herein is an armor panel element that is resistant togauging and other surface deformation that exhibits antiballistic and/orblast resistant characteristics, that includes a polymeric substratecontaining at least one of ultrahigh molecular weight polyethylene andaramids, the polymeric substrate having at least one face and apolymeric coating composition adhered in overlying relationship with atleast a portion of the face. The polymeric coating composition iscomposed of a plural component system as disclosed herein.

The present disclosure also is directed to a device or vehicle having atleast one panel composed of a polymeric substrate material and a coatinglayer in overlying adhered relationship with at least one face definedin the polymeric substrate. The coating layer includes a polymericcomposition composed of a plural component polymeric system that is areactive blend of at least one first component and at least one secondcomponent. The first component of the reactive blend consistsessentially of a polymer and/or blend of polymers present in an amountsufficient to impart tensile strength hardness, flexibility, andadhesive strength to the resulting polymeric coating. The secondcomponent is an iso-cyanate or isocynate quasi-prepolymer.

The present disclosure also includes various armor embodiments havingvarious reinforcements and supports to provide armor panels suitable foruse in high traffic areas or areas that will experience heavy loading,wheeled equipment loading, etc.

The armor panels can be individually configured to fit or be fitted intothe interior of the associated vehicle. The armor panels can be ofvarious configurations to correspond to the desired interior of thecorresponding vehicle. The nature and type of added panel reinforcementscan vary depending upon the intended location in the associated vehicle.It is contemplated that the armor panels can be collated into a kit thatcan be installed in an associated vehicle as desired or required.

Non-limiting examples of polymeric substrate materials to which thecomposition disclosed herein can be applied include ultrahigh molecularweight polyetheylenes (UHMWPE) as well as various aramids. Non-limitingexamples of suitable UHMWPE materials include materials commerciallyavailable under the trade name DYNEEMA from DSM and SPECTRA fromHoneywell. Non-limiting examples of suitable aramids include KEVLARcommercially available from DuPont. The polymeric substrate material canbe formed into suitable structures that can be employed in variousend-use applications.

It is contemplated that various formulations can be employed whereUHMWPE is desired. These materials include, but are not limited to,materials such as DYNEEMA. Without being bound to any theory, it isbelieved that DYNEEMA materials are UHMWPE composites incorporatingfibers of ultrahigh molecular weight polyethylene in a polymeric matrix.

Where desired or required, fibers of UHMWP can be laid parallel to oneanother in the same plane with the direction of fibers in each layerpositioned at 90.degree. to the direction of the fibers in adjacentlayers. Such material is commercially available under the trade nameDYNEEMA UD. Suitable materials can be formed as a compressed stack ofmonolayers with each monolayer containing unidirectionally orientedreinforcing fibers and a plastic matrix material. One nonlimitingexample of a suitable material and process is outlined in U.S. Pat. No.6,183,834, the specification of which is incorporated herein byreference.

Nonlimiting examples of suitable aramid-based materials suitable for useas the substrate material include materials commercially available underthe trade name KEVLAR or TWARON.

Materials such as KEVLAR are believed to be para-aramid synthetic wovenfibers that can be integrated into substrate panels. It is believed thatvarious meta-aramids such as NOMEX may be utilized in certainapplications.

In various non-limiting examples contemplated herein, the polymericmaterial can be formulated as armor plating and reinforcement toincrease the ballistic and/or blast-resistance of the associated deviceor vehicle. As used herein, the term “ballistic resistance” is taken tomean the ability of the particular structure to prevent or impede theforward travel of ordinance through the polymeric material. Ballisticresistance can be taken to include but need not be limited to theability of a material to prevent or impede forward travel of bullets,shrapnel and the like. “Blast resistance” is taken to mean resistance toconcussive force associated with an explosion or similar event.Resistance can include mitigating and/or damping of the intensity of theevent as well as any reduction in forward travel or other ill-effects.

Where ballistic resistance and/or blast resistance is desired orrequired, it is contemplated that that one or more of the substratematerials outlined above can be formulated as thick structure orcomponent that will exhibit desired blast resistance and ballisticresistance characteristics. In certain applications and configurations,it has been found that such materials can stop forward progress of a 50caliber ammunition round. Without being bound to any theory, it isbelieved that this is due, at least in part to, localizedchange-of-phase phenomena and characteristics of heat dissipationexhibited in the polymeric material.

The polymeric substrate material can be formed in any suitablestructural configuration. In certain embodiments, it is contemplatedthat the substrate will be in the form of sheets or panels; however itis contemplated that other geometric forms can be successfully employedin certain embodiments. The substrate material can be formed by anysuitable process such as various molding or extrusion processes and willhave dimensions suitable for the desired end-use applicationcontemplated. It is contemplated that the material will have suitabledimensional thickness to prevent or impede the transit of ballisticmaterial and/or blast waves through the panel on to any internal spaceor structure.

Where the resulting construct is to be employed as armor for associatedaeronautical or automotive vehicles, it is contemplated that thematerial will have suitable dimensional thickness to prevent or impedethe passages of ballistic material such as armored rounds or shrapnelfrom transiting the panel. It is to be understood that the associateddimensions may vary from application to application depending upon thespecifics of the end use. It is also understood that the specificdimensions and/or geometry of various panels will vary depending uponfactors such as placement of a specific panel relative to the locationand fixtures found in the associated vehicle. The thickness of the givenpanels will be sufficient to meet the ballistic requirements of a givensituation. In certain embodiments, it is contemplated that the materialfabricated in 1 inch panels will exhibit sufficient ballistic dampingcharacteristics to stop the forward travel of a 50 caliber round ofammunition.

It is contemplated that the substrate material can be formulated in topanels of a thickness of approximately 2 inches in many end-useapplications. The length and width dimensions can be varied to conformto the structure in which the panels are to be used. It is contemplatedthat the panels can be positioned and affixed to the associatedstructure in any manner that imparts enhanced ballistic and/or shockresistance in many end-use applications. By way of nonlimiting example,it is contemplated that a panel or panels can be attached to the floorand/or walls of the interior region of the various helicopter units toprovide ballistic and/or blast protection to personnel and cargocontained therein. In various embodiments, it contemplated that thepanels can be removably attached in overlying relationship to floorand/or wall structure or substructure existing in the helicopter unit.It is also contemplated that one or more of the panels can be placed indirect contact with joists or other structural members of the helicopterwhere desired or required.

One non-limiting example of an embodiment of armor panel is depicted inFIG. 1. Armor panel 10 includes substrate panel member 12. The substratepanel 12 can be of any suitable size to be positioned in the interior ofthe desired vehicle. One non-limiting example of a suitable vehicle is ahelicopter unit. Other non-limiting examples of suitable vehicles andarmor applications in clued automotive vehicles, land and sea-basedpersonnel carriers. The armor panel can be used in flooring orientationsas well as other locations on the vehicle of choice. In certainembodiments, the substrate panel may encompass the entire floor or wallsurface of the vehicle interior. However, in various embodiments, it iscontemplated that the substrate material can be configured in individualpanels that can be removably attached to the floor and/or wall inindividual units to facilitate positioning and future repair orreplacement.

The substrate panel 12, an upper face 14 and a lower face 16 as well asside edges such as side edges 18, 20. A polymeric coating compositionlayer 22 overlays at least one face of the substrate panel 12. Incertain embodiments, the substrate panel 12 is encased with a polymericcoating composition layer 15. At least one non-limiting example of asuitable polymeric composition is one such as that described herein.Where desired or required, the polymeric composition layer 22 can be indirect contact with at least a portion of the substrate panels 12.

In various embodiments, the composition layer will encase the associatedsubstrate panel 12 to form an armor panel 10 with a layer of suitablepolymeric coating in overlying relationship there to. In suchapplications, the thickness of the polymeric layer can be between 0.01and 0.25 inches thick with thicknesses between 0.04 to 0.10 beingemployed in some embodiments.

The panel configurations made up simply of a coating composition layer14 attached to the substrate on at least one face can be employed invarious locations to armor the associated vehicle. It is contemplatedthat the panels so configured can be advantageously positioned in areasthat experience relatively lower wear and/or traffic patterns. Suchpanels can be employed in other locations as desired or required.

While the substrate materials described herein is discussed inconjunction with armor panels, it is to be understood that the polymericmaterial of the substrate and the associated coating may be employed inother end use applications as desired or required. It is also understoodfrom the disclosure contained herein that the composition may be appliedto various polymeric substrates surfaces having limited or challengingadhesion characteristics in order to reinforce the polymeric surface andlimit undesirable wearing problems such as flaking chipping, gouging andthe like. Non-limiting examples of challenging adhesion characteristicscan be quantified as surfaces that are difficult to wet that have lowsurface energy with a Dyne level reading of less than 30.

It is contemplated that the coating composition as disclosed herein canbe applied and connected to the substrate such that the coatingcomposition overlies at least a portion of the polymeric substratematerial. It is contemplated that the coating composition may directlycontact the associated substrate surface in various embodiments. Inalternate embodiments, it is contemplated that at least one intermediatelayer can be interposed between the coating layer and the polymericsubstrate surface. The interposed layer can function as a tie layerwhere desired or required.

The coating material can be applied as a layer overlaying at least aportion of the substrate surface. The coated portion may be applied toan individual face of the substrate or a portion of the individual faceas desired or required. Typically the area coated will be one exposed towear, abrasion or the like. In other embodiments, it is contemplatedthat the coating material will be applied in a manner that coversmultiple faces of sides of the substrate or completely encases theassociated polymeric substrate.

The coating material applied to the polymeric substrate can have asuitable thickness to protect the associated polymeric substratematerial. In various embodiments, it is contemplated that the coatingmaterial can be applied in a manner that encases the substrate in amaterial of essentially uniform thickness. It is contemplated thatcoating thicknesses between 25 and 80 mils (0.64 to 2 mm) can beemployed in certain embodiments. It is also contemplated that coatingthicknesses between 40 and 50 mils (1.0 to 1.3 mm) can be employed invarious embodiments.

The coating composition disclosed herein can reduce or eliminatedegradation of the surface and/or the internal structure of thepolymeric substrate material. It is contemplated that surfacedegradation and/or internal structural degradation of the polymericsubstrate material may be due, at least in part, to the inherentphysical characteristics of the substrate material including but notlimited to characteristics such as friability of the substrate materialas well as the external physical challenges associated with general useof the associated construct in day-to-day activities including, but notlimited to, chipping, gauging and the like. It has been found, quiteunexpectedly that the construct disclosed herein exhibits enhancedstructural wear resistance and strength. It has been further ascertainedthat ballistic resistance and/or blast resistance characteristics of theassociated polymeric substrate material are not unduly impaired by theaddition of the coating material. Such resistance characteristics may beexpressed and evidenced by phenomena including but not limited to heatdissipation and localized change of phase phenomena. In certainembodiments, it is contemplated that the coating composition may enhancethe ballistic resistance and/or blast resistance of the resultingconstruct. Without being bound to any theory, it is believed thatencasement in the coating composition disclosed herein providessurprising integration of the panel substrate that translates infointegrated translation in response to deformation flex particularly inblast events.

Where it is anticipated that the armor panel(s) 10 may experiencegreater traffic or wear, the armor panels 10 can be configures with asuitable panel cap 22 overlying one or more side edges of the planarsubstrate 12, such as side edges 18, 20. As depicted in FIG. 4, theregion of the upper and lower surfaces 14, 16 proximate to theassociated side edge such as side edge 18 can be configured with asuitable geometry to conform and accept the channel cap element 22. Inthe embodiment depicted in drawing FIGS. 1-4, the upper and lowersurfaces are configured with complementary bevels or detents 24, 24′.One or more sides of the panel can be configured with a suitable panelcap 22. In the embodiment depicted in FIG. 1, the panel cap 22 canextend around all sides of the substrate panel member 12.

The panel cap 22 can be constructed of suitable polymeric or metallicmaterial capable of capping and strengthening the associated side edgeof the substrate panel member 12. In the embodiment depicted in FIG. 4,the substrate panel cap 22 has a central body 26 and two opposed wallmembers 28, 28′ extending essentially perpendicularly from the centralbody 26 to define a central channel configured to receive the associatedside of substrate panel member 12 in mating relationship therein. Invarious embodiments, the wall members 28, 28′ extend sufficient distancefrom the body 26 to contain a substantial portion of the bevel region ofthe substrate panel member 12 therein. The wall members can have athickness generally equal to the thickness reduction found in the bevelregions. The channel cap member can be maintained in position by anysuitable means. The substrate panel cap 22 can be maintained by suitableposition by mechanical fit or by use of a suitable adhesive interposedbetween the substrate panel member 12 and the interior channel definedin cap 22. One non limiting example of a suitable adhesive capable ofaffixing the panel cap in adhered relationship with the associated panelmember 12. Suitable adhesive materials include, but are not limited tovarious curable polymeric materials such as suitable two part adhesivecompounds. Non-limiting examples of such adhesives include materialssuch as those marketed under the trade name HYSOL commercially availableform Henkel Corporation. Such materials are believed to be two-partepoxy-based adhesives. Suitable HYSOL materials include compositionsmarketed under the trade designation HYSOL EA9309.3NA. It is believedthat HYSOL is a two part epoxy compositions that self cures and iscomposed of an “A” component containing epoxy resin and a “B” componentcontaining a suitable diethylene glycol aminoalkylether.

The substrate panel cap 22 can have any suitable configuration. In theembodiment depicted in FIG. 4, the panel cap 22 has a U-channelconfiguration. The device 10 can be configured with the U-shaped channelin position in one or more of the side regions of the panel member 12.Thus in certain embodiments, the panel cap 22 can be positioned on oneor more sides of the associated panel member 12. Alternately, the panelcap can surround the entire perimeter of the associated panel member 12.

Where the panel cap 22 surrounds or overlies corner regions of the panelmember 12, the panel cap 22 can have rounded radius junctions betweenadjacent panel edges where desired or required.

The panel cap 22 can also be variously configured with a suitable regionto connect with adjacent substrate panel members 12 and 12′. One nonlimiting embodiments of a suitable configured U-channel 22′ is depictedin FIG. 5 as a structure connection member configured to connect tofirst panel member 12 and second panel member 12′. The respectivesubstrate panels 12, 12′ can be held in place by mechanical fit and/orby suitable adhesives interposed between the respective panel substratemember and the panel cap. Where desired or required, the multi-panelconstruction can also be configured with a U-shaped panel cap 22 alongone or more outside edges in the manner described previously.

The panel cap 22 can also be configured with suitable slots and bracesto accept bolts, screws, and various clamps and structural membersneeded in construction in the associated vehicle. Such slots and braces(not shown) can be employed variously in order to anchor the armor panel10 to structural members in the associated vehicle and/or to attachother devices or members to the armor panel 10.

As configured, the armor panel 10 with panel cap 22 in position iscoated with the coating composition in the dimensions as outlinedpreviously. Thus the coating composition layer 15 overlies the constructof panel cap 22 and substrate panel member 12 and can encase the panelcap 22 therein.

The reinforced armor panels can be installed in an edge-to-edge mannerin the associated vehicle. In certain particular installations,unreinforced armor panels composed of the substrate panel 12 and coatinglayer 14 can be installed in low traffic areas for instance inhelicopter cockpits and the like. Panels reinforced with suitable panelcap(s) 22 can be used in areas of the vehicle that experience higherlevels of foot traffic such as vehicle doorways and the like. Panelcap(s) 22 configured to form a joint between two adjoining panel memberscan also be employed to form a larger surface area and reinforce thecentral rejoin defined therein.

Kick guard(s) 30 can be affixed to various substrate panel members 12 atlocations that will correspond to vehicle step(s) and the like. In theembodiment depicted in FIG. 1, kick guard 30 can be attached to thepanel 12 by any suitable mechanism. In various embodiments the kickguard(s) 30 can be riveted to the upper face of the armor panel 10 inoverlying relationship to the coating composition layer 15. Attachmentcan be by any suitable mechanism for example by using suitable rivetfixtures positioned in panel member 10. The kick guard 30 can be formedfrom any suitable metal or polymeric material. In various embodiments,the hick guard can be affixed in overlying relationship to the coatingcomposition layer 15.

The armor panel 10 can also be configured with suitable reinforcedlaminated layer(s) or skin 32. The skin 32 can be attached in overlyingrelationship to all or a portion of the outwardly oriented surface ofthe armor panel 10 when it is in the use position. The skin 32 can becomposed of one or more layers of suitable woven or nonwoven polymericmaterial. The layer or layers that may contain reinforcing material suchas carbon fiber or the like. In one embodiment, the skin 32 can becomposed of at least one layer having a carbon fiber reinforcementmaterial. One non-limiting example of suitable reinforced laminatedlayer material is polymeric film materials composed of carbon fiberentrained in a suitable polymeric resin matrix at levels between about0.05% and about 10% carbon fiber to resin.

Reinforcement skin 32 can be adhered over the polymeric coating layer 14using any suitable method that will provide good adhesion through theuseful life of the pane 101. In the embodiment depicted, thereinforcement skin 32 skin is adhered to the polymeric coating layer 14by a suitable adhesive layer interposed therebetween. Non limitingexamples of such adhesive include suitable acrylate copolymericadhesives such as acrylate copolymeric adhesives.

Where desired or required to promote adhesion, the armor panel 10 caninclude a suitable primer layer 52 interposed between the adhesive layerand polymeric coating layer. Suitable primer materials include but arenot limited to primers such as surface primers commercially availablefrom 3M under the trade designation Primer 94 used alone or with 3M 468MP. 3M Primer 94 is believe to be an acrylate polymer in admixture witha chlorinated polyolefin and epoxy resin in a solvent matrix ofmaterials such as cyclohexane, xylene, ethyl alcohol, ethylbenzene andthe like. Materials such as 3M 468 MP are formulated as an adhesivetransfer tape that is believed to be an acrylate copolymer adhesive Suchmaterials can be employed to promote adhesion between the coating layer14 and various overlaying materials including the adhesive layer.

In situations where the armor panel 10 is to be positioned in locationsin the vehicle that will experience heavy traffic and/or vehicle orheavy wheeled equipment loading, it is also contemplated that the armorpanel 10 will include a foam spacer or base layer 60 that can be adheredto the polymeric coating layer 15 in any suitable manner. The foamspacer layer 60 will be positioned on the panel 10 so that it isoriented toward the vehicle exterior in a “downward” use orientation.

The foam base layer 60 can be a suitable open- or closed-celledpolymeric material that exhibits deflection and deformability underload. The foam base layer functions as a spacer that cushions the panelmember when in position in the vehicle. The foam base layer can be ofany suitable thickness with thicknesses between 0.1 and 0.5 beingemployed in some embodiments. The foam base layer may extend over someor all of the lower face of the panel. In certain embodiments, the foambase layer can extend over the lower face of the panel to a pointproximate to the associated U channel member.

In certain embodiments, the foam layer 60 can be adhered using asuitable spray adhesive applied either directly to the polymeric coatingor to an intermediate primer layer such as primer layer 52. Suitablematerial will have high contact bond strength and rapid set up time. Onenon limiting example of a suitable adhesive is 3M HI-Strength 90 sprayadhesive. Other materials are also contemplated as desired or required.

The coating composition employed in the coating composition layer 15 canbe one that adheres to the surface of the substrate panel member 12.Suitable materials can be is formed from a plural component system thatincludes at least one first component and at least one second componentthat are reactively admixed prior to or upon contact with the substratesurface. The first component of the plural component system is anisocyanate component. The isocyanate employed herein will be anisocyanate material having high aromatic functionality. In variousembodiments, it is contemplated that the isocyanate component willinclude an aromatic isocyanate prepolymer or quasi-prepolymer that isbased upon a blend of a suitable aromatic diisocyanate and/or aprepolymer of a suitable diisocyanate and a suitable high molecularweight polyol.

Suitable aromatic diisocyanates employed in the prepolymer or quasiprepolymer include, but are not limited to, various alkyl and dialkyldiisocyanates, of which methylene diphenyl diisocyanate, toluenediphenyl diisocyanate, and hexamethylene diphenyl diisocyanate arenon-limiting examples. Suitable high molecular weight polyols includebut are not limited to various polyether polyols of whichpoly(tetramethylene ether) glycol polyols are but one non-limitingexample. In various embodiments, it is contemplated that a suitablearomatic isocyanate quasi prepolymer, based upon a blend of an aromaticliquid MDI and a prepolymer of TDI and a p-TMEG polyol. One example ofsuch material can be commercially obtained under the trade nameINNOVATHANE® 101 from Air Products Corporation. It is contemplated thatvarious embodiments can employ an aromatic quasi prepolymer of liquidMDI and a p-TMEG polyol where desired or required.

Additional non-limiting examples of aromatic polyisocyanate is methylenebis(4-phenylisocyanate) or “MDI.” Pure MDI, quasi-prepolymers of MDI,and modified pure MDI, etc., are useful. Materials of this type may beused to prepare suitable elastomers. Since pure MDI is a solid and,thus, inconvenient to use, liquid products based on MDI are alsodisclosed as suitable for use in the present invention. For example,U.S. Pat. No. 3,394,164, which is incorporated herein by reference,describes a liquid MDI product. More generally, uretonimine modifiedpure MDI is also included. This product is made by heating puredistilled MDI in the presence of a catalyst. Examples of commercialmaterials of this type are ISONATE® 125M (pure MDI), ISONATE® 2143L (aliquid uretonimine-modified methylenediisocyanate product), RUBINATE®1680 (a liquid uretonimine-modified methylenediisocyanate product),RUBINATE® 1209, RUBINATE® 9009 (an aromatic isocyanatequasi-prepolymer), RUBINATE® 9015 (an aromatic isocyanatequasi-prepolymer), and RUBINATE® M (“liquid” MDI's). The ISONATE®products are available from Dow Chemical Co. in Midland, Mich., and theRUBINATE® products are available from ICI Polyurethanes located in WestDeptford, N.J.

It is contemplated that the quasi prepolymer of the isocyanate componentof the plural component system can be reacted with a sufficient quantityof a suitable high or increased functionality diisocyanate to form thereactive isocyanate component of the plural component system. Suitablehigh or increased functionality diisocyanates include, but are notlimited to, diisocyanates with functionality of 2.0 or greater.Non-limiting examples of suitable high functionality isocyanates includematerials having a percent NCO between about 25 and 35. Highfunctionality isocyanates can be based upon polymeric methylenediisocyanates modified to provide functionalities of 2.90 to 3.0 andpercent NCO between 20 and 35%, with percentages between 22% and 32%being employed in certain situations. Non-limiting examples of suchmaterials include RUBINATE 9257 and SUPRASEC 9582 commercially availablefrom Huntsman Polyurethanes. It is believed that RUBINATE 9257 is apolymeric methylene diphenyl diisocyanate modified to provide afunctionality of 2.9 and a percent NCO of 30.1.

Where desired or required, the isocyanate portion can also optionallyinclude suitable additives such as fire retardants and the like.Non-limiting examples of suitable fire retardant compounds that can beincorporated into the isocyanate portion of the plural componentcomposition disclosed herein. Non-limiting examples of such fireretardants include Tris-(Chloropropyl)phosphates and the like. Suitablematerials are available from under the trade name Antiblaze 80/FyrolPCF. Where a flame retardant is incorporated, it is contemplated thatthe compound or compounds can be present in an amount sufficient toimpart flame retardance or resistance to the resulting composition withamounts between 0 and 10 pbw of the isocyanate composition beingcontemplated in various instance.

It has been found unexpectedly that materials such asTris-(Chloropropyl) phosphates and the like may help to lower theviscosity and enhance processability and application characteristics ofthe resulting coating system.

It is contemplated that the isocyanate portion can be composed of one ormore isocyanate compounds. The isocyanate compounds can be present inthe isocyanate portion in amounts between 95 and 100 pbw of theisocyanate portion of the composition. Where blend of isocyanatematerials are employed, it is contemplated that the isocyanate componentcan be a blend of between about 70 and 100 pbw quasi isocyanateprepolymer and between 0 and 30 high functionality diisocyanatematerial, with 70 and 95 pbw quasi isocyanate prepolymer and between 10and 25 pbw high functionality diisocyanate material in variousembodiments of the composition.

The isocyanate portion of the composition disclosed herein can beformulated to provide a suitable available NCO content upon blendingwith available NCO contents between about 15 and about 18% upon blendingbeing desirable in at least some embodiments.

The coating material as disclosed herein is a two-component systemprepared from the reactive admixture of the suitable isocyanatecomponent such as s those previously enumerated with a suitable resin orpolymeric component in sufficient quantity and reactive ratio to producetensile strength, hardness and flexibility properties that are requiredfor this given application. Reactive ratios can be between 1.00:1.00 and1.50:1.00, isocyanate to resin.

The polymeric component of the reactive admixture is one that can beemployed to represent the backbone of the composition. It is to beunderstood that any suitable polymers may be used. Non-limiting examplesof suitable polymers include, but are not to be limited to,amine-terminated polyetherpolyols, amine-based tetrol polyols, highfunctional polyols, amine-terminated chain extenders, and the like.

Suitable amine-terminated polyether polyols suitable for use in thecomposition disclosed herein include amine-terminated polypropyleneglycol having a molecular weight between 400 and 4000. Typical averagemolecular weights for suitable materials in certain applications wouldbe in the range of 2000. Non-limiting examples of suitable materialshaving amine-terminated polyether polyol functionalities includeJEFFAMINE D-2000 from Huntsman Polyurethanes and Polyether Amine D-2000from BASF Corporation. It is believed that materials such as JEFFAMINED-2000 and Polyether Amine D-2000 are difunctional primary aminepolyetheramines with an average molecular weight of approximately 2000.Where desired or required, various other difunctional amines within thisclass can be employed in combination with the difunctional primary aminepolyetheramines or in place of these materials. It is contemplated thatthe amount of difunctional amine employed can be between 10 and 80 pbw,with amounts between 20 and 40 pbw being utilized in specificapplications in the initial formulation. In specific automotiveapplications, it is contemplated that the amount of difunctional amineemployed can be between 10 and 20 with amounts between 15 and 18 pbw ofthe resin blend being utilized in specific applications.

Amine-based tetrol polyols are those characterized as tetrafunctionalpolyols initiated from ethylene diamine. Non-limiting examples ofsuitable materials will typically have a hydroxyl number in the range of700 to 800. Suitable materials can be derived from ethylene diamine andpropylene oxide or ethylene diamine and mixtures of ethylene oxide andpropylene oxide. Amine-based tetrol polyols can include variouspolyether polyol aliphatic amine initiated tetrols present in amountsbetween 15 pbw and 40 pbw. In specific formulations in certainembodiments, it is contemplated that the amine-based tetrol polyols canbe present in amounts between 8 pbw and 25 pbw. Non-limiting examples ofsuch materials include VORANOL 240-700 or VORANOL 800, which arebelieved to be ethylene diamine and ethylene oxide/propylene oxideadduct polyols commercially available from Dow Chemical. Other usefulmaterials include ethylene diamine propylene oxide adduct polyolsavailable from BASF Corporation under the trade name QUADROL.

High functional polyols can also be effectively employed. Thesematerials are typically characterized as tetra or pentafunctionalpolyols of propylene oxide initiated from pentaerythratol or sucrose.Suitable high functional polyols can have a molecular weight in therange of 400 to 600. Without being bound to any theory, it is believedthat these polyols provide for cross-linking of the polymer andresulting stiffness and hardness without embrittlement. Non-limitingexamples of such materials include secondary polyether tetrols having ahydroxyl number between about 200 and about 800. Such materials includePLURACOL PEP 550, commercially available from BASF Corporation. Incertain specific embodiments, it is contemplated that the secondarypolyether tetrol will have a hydroxyl number between about 450 and about550.

The resin component of the composition of the composition disclosedherein may further optionally include a chain extender and/or a blend ofchain extenders present in an amount sufficient to impart apredetermined amount of tensile strength, weatherability, flexibility,adhesion to specific substrates, and hardness to the overall system.Where employed, the chain extender component can be present in an amountbetween 1 and 25 pbw, with amounts between 10 and 20 pbw being presentin certain applications. It is believed that the chain extender(s) mayalso adjust the reaction rates of the overall system. Amine-terminatedchain extenders can be characterized as diamines that are either primaryor secondary in nature. These can either be aromatic or aliphatic basedresins.

Suitable chain extenders are selected from the group consisting ofdialkyl substituted methylene dianiline, diethyltoluene diamine,substituted toluene diamines, and mixtures thereof. Other suitable chainextenders may include amine terminated aliphatic chain extendersselected from (but not limited to) the group consisting of cyclohexanediamine, isophorone diamine, and mixtures thereof. Other suitable chainextenders may include low molecular weight glycol type chain extenders,such as, for example, 1,4-butane diol. Non-limiting examples of primaryaromatic amines are ETHACURE 100 (DETDA: Diethyl toluene diamine), andETHACURE 300 (DMTDA: Dimethyl thiotoluene diamine) from AlbemarleCorporation.

It is contemplated that the resin component may contain various dualfunction compounds. One non limiting example of a suitable dual functioncompound is melamine. Without being bound to any theory it is believedthat melamine functions as a chain extender and also possesses fireretardant capability. Where employed in the resin component, it iscontemplated that melamine will be present in an amount between 2 and 5pbw. One non limiting example of suitable melamine material iscommercially available from DSM Melamine Americas, Inc.

The resin component may include suitable fillers and additives asdesired or required. In certain embodiments, it is contemplated that theresin component may include various materials added as pH modifiersand/or to alter and affect heat resistance of the finished composition.Non limiting examples of such materials include various multivalentmetal borates.

Suitable multivalent metal borates are those of divalent metals,particularly metals of Group II of the Periodic Table, and especiallythe borates of zinc and calcium. Borates having low oil absorbency canbe employed effectively with good results obtained with zinc borate. Theamount of multivalent metal borate added to the composition is usuallyat least 5% by weight, based on the weight of the polymeric substrate.

Non-limiting examples of suitable fire retardant materials includecompounds such as magnesium hydroxide, calcium hydroxide, bariumhydroxide, sodium tetra borate decahydrate, or pentahydrate, sodiummetal borate tetrahydrate, sodium tetraborate, sodium carbonate,hydrates of sodium carbonate, sodium citrate and hydrates thereof, andsimilar compounds of potassium, lithium and ammonium, pyridine, pyrrole,2-aminoethylpropanol, benzylamine, n-butylamine, t-butylamine,ethylamine, ethylenediamine, hexamethylene diamine, methylamine,3-aminopentane, 3-amino-3-methyl pentone, piperazine,1,3-diamino-propane and propylamine and the like.

The resin component may also contain suitable additional fire retardantmaterials including but not limited to silica or silica flour, barytes,talc, aluminum trihydrate, calcium carbonate, ammonium phosphate and thelike. The additional fire retardant component can be present in theresin component in any suitable amount with quantities between about 0and 7 pbw based on the resin component being contemplated. In variousspecific embodiments, it is contemplated that the additional fireretardant material will be aluminum trihydrate.

It is contemplated that one or more of the fire retardant materials canbe present in the resin component at particle sizes at or below nanoparticulate levels. The resin component may also contain suitableadditional fire retardant material including but not limited toexpandable graphite. It is believed that various expandable graphitesare nano particulate graphite. Expandable graphite would include but isnot limited to commercial material such as Nyacol Nyagraph from NyacolNano Technologies, Incorporated.

The resin component can also include classes of fire retardantstypically referred to as brominated fire retardant materials. Inaddition to fire retardancy, these also offer smoke suppressioncharacteristics. Suitable materials may include various brominatedaromatic compounds. Where employed, these brominated materials will bepresent in amounts between 10-15 pbw. Examples of these include but arenot limited to SAYTEK 102E from Albemarle Corporation.

The resin component of the composition disclosed herein may furtheroptionally consist essentially of any suitable colorants, pigments, orthe like, as desired. Some non-limitative examples of such materials areselected from the group consisting of carbon black, titanium dioxide,iron oxide (a suitable iron oxide is commercially available under thetrade name RED OXIDE from Harcros Chemicals, Inc., Kansas City, Kans.),organic pigments and dyes, and mixtures thereof. These compounds areused primarily to impart a specific color to the composition. However,in some instances, carbon black and titanium dioxide, for example, mayalso affect the hardness of the system. Where employed, pigmentmaterials can be present in amounts suitable to impart the desiredcoloration in the finished composition as applied. In variousembodiments contemplated herein, pigment material is present in theresin component in amounts between 0 and 12 pbw of the initial resincomponent, with amounts between 7 and 10 pbw being contemplated in someembodiments.

It is also contemplated that the resin component include suitableadhesion promoters as desired or required. Non-limiting examples ofadhesion promoters include chlorinated polyolefins and polyester basedresins. Non-limiting examples of chlorinated polyolefins includematerials commercially available from Eastman Chemical under the tradename of Eastman CP series. Non-limiting examples of polyester basedresins include materials commercially available from King Industriesunder the trade name of K-Flex. Suitable materials can include K-Flex188. Where employed, it is contemplated that the adhesion promoter canbe present in amounts between about 0.15 and 5 pbw resin component withamounts between 0.5 and 2 pbw being contemplated in certain embodiments.

It is also contemplated that the resin component can be formulated withsuitable fungicides, algaecides and the like. Suitable materials includevarious thiophenols of which zinc pyrithione is one non limitingexample. Zinc pyrithione is commercially available from Arch Biocidesunder the trade name Zinc Omadine. Where employed it is contemplatedthat the fungicide material will be present in an amount between 0.001and 0.01 pbw.

The isocyanate and resin component can be formulated to provide an indexof 1.05 to 1.20 with indexes of 1.10 to 1.15 being applicable in certainapplications. It is contemplated that these components can be mixedeither using high pressure impingement mixed spray equipment or lowpressure static-mixed extrusion techniques.

It is also contemplated that the coating composition disclosed herein isa two-component system prepared from the reactive admixture of asuitable isocyanate component with a resin or polymeric component insufficient quantity and reactive ratio to produce tensile strength,hardness, adhesion and flexibility properties that are required for thegiven application. Reactive ratios can be between 1.00:1.00 and1.50:1.00.

The coating composition can be applied to the desired substrate in anysuitable manner, including, but not limited to, multi-componentapplication techniques. It is contemplated that the coating compositioncan be applied in overlying relationship with the substrate usingsuitable spray and/or hot melt application techniques, including, butnot limited to extrusion. The material can be applied to at least onesurface region by any suitable application technique. It is contemplatedthat the material will be applied in a liquid or semiliquid state andwill solidify completely after application. Solidification may be due inwhole or in part to temperature decrease or may be due to cross-linkageformation depending upon the type and nature of the polymericcomposition.

The resulting device or construct comprises a substrate element with amulti-component polymeric composition affixed in layered relationship toat least one surface region. In certain embodiments, the resultingconstruct will be composed of a molded substrate composed of a friablepolymeric material with a coating composition overlaying at least aportion of the substrate surface. The substrate can be configured as apanel or other suitable geometric configuration. The coating materialwill have a suitable thickness with coating thicknesses sufficient toprotect the underlying substrate from gauging, degradation and the likewith thicknesses between 25 and 80 mils (0.64 and 2 mm) beingcontemplated in certain embodiments.

In various other embodiments, it is contemplated that the substrate canbe encased in coating material applied at a thickness sufficient toprotect the underlying substrate from gauging, degradation and the like.It is contemplated that the coating thickness will be that sufficient toprotect the underlying substrate based upon the end use application. Incertain embodiments, it is contemplated that thicknesses between about25 and 80 mils (0.64 and 2 mm) can be employed.

In certain embodiments, it is contemplated that the substrate materialwill be composed of UHMWPE materials such as DYNEEMA formed into panelstructures of sufficient thickness to impede transit of ballisticmaterials such as bullets and shrapnel and the like. It is contemplatedthat the resulting panels can be positioned as floor panels in variousvehicles such as helicopters and the like. Without being bound to anytheory, it is believed that that the construct disclosed herein in whichthe a suitable antiballistic material such as DYNEEMA is coated with thecoating material outlined herein provides a durable construction inwhich the coating is integrally connected to the substrate surface inoverlying relationship thereto.

The resulting coating material is a plural component system that can beapplied to the substrate in any suitable manner. Broadly construed, itis contemplated that the application method can comprise the steps ofadmixing an isocyanate component as disclosed herein with a resincomponent as disclosed herein to form a plural component system;dispatching the plural component system at elevated temperature and highpressure; and applying the plural component system onto at least aportion of difficult to coat substrate and/or other surface.

The plural component system is preferably applied at high pressure andelevated temperature using suitable spray equipment. In manyapplications, it is contemplated that the spray applicator will be atwo-component system. In general, it is contemplated that elevateddynamic pressure in a range between 1500 psi and 2500 psi can besuccessfully utilized. It is also contemplated that the applicator willbe one that utilizes elevated temperature in at least a portion of themixing and/or application process. It is contemplated that material canbe mixed and applied at an elevated temperature in a range between 110degrees F. and 170 degrees F. The material is uniquely formulated forrobotic application and impingement mix dispensing where mix ratiotolerance is required.

The resulting plural component material can be applied to the associatedstructure in a manner that provides a final layer thickness between 20mils and 80 mils. It is contemplated that the material layer thicknesscan be essentially consistent throughout the layer. However wheredesired or required, the layer thickness can be varied over the coveragearea, for example, in order to accommodate excessive wear areas and/orirregularities in the underlying surface area. It is also contemplatedthat the thickness of the applied material can be varied based on thespecific region of the substrate to be coated. As a non-limitingexample, it is contemplated that the thickness of the coating to beapplied can be increased or deceased over corners, edge regions and thelike as desired or required.

The coating system disclosed herein can be applied by any suitablemethod. The method chosen will typically provide for reactive admixtureof the various components at a point in the application process suitablefor promoting liquid or semi-liquid administration of the polymericmaterial to the surface of the substrate with additional solidificationof the applied material occurring after contact with the substrate. Itis contemplated that solidification can include physical solidificationas the temperature of the applied material drops after application.However, in many instances, it is contemplated that the chemical crosslinking will commence with the contact between the various componentswith the cross linking reaction(s) proceeding to a point prior toapplication that will still facilitate application and adhesion to thesubstrate surface with the cross-linking reaction continuing postapplication.

The dual component material can be processed in any manner suitable toprovide and promote the reactive admixture and application of theresulting material. Thus, where desired or required, the materials canbe processed at elevated pressure and/or temperature. As used herein,the terms “elevated temperature” and “elevated pressure” are defined asvalues above standard temperature and pressure (STP). In certainsituations, it is contemplated that one or both values will be aboveambient. The temperature and/or pressure elevation can be that necessaryto achieve reactive admixture and maintain the material in a suitablestate for application. It is contemplated that elevated temperature willbe at least 25.degree. C. above standard temperature with an uppertemperature elevation being limited to the decomposition temperature ofone or more of the component materials. In certain applications,temperature elevation will be at least 35.degree. C. above standard. Itis also contemplated that one or more of the component process streamscan be preheated prior to reactive admixture. The preheat temperaturefor a given component can be affected for a variety of factorsincluding, but not limited to, altering physical characteristics of thecomponent stream, non-limiting examples of which include viscosity. Itis also contemplated that the temperature of a given component streamcan be elevated to enhance or promote the reaction upon admixture withone or more additional components or component streams. Introductiontemperatures for one or more of the component streams can be at least25.degree. C. above standard, with temperature elevations of at least35.degree. C. being contemplated in certain embodiments.

It is contemplated that in such dual component systems, the (A)component and the (B) component of the coating system are combined ormixed under high pressure; most preferably, they are impingement mixeddirectly in the high-pressure spray equipment. Non-limiting examples ofsuitable spray mixing equipment include various units available underthe following trade names: GUSMER H-2000, GUSMER H-3500, GUSMER H-20/35,and Glas-Craft type proportioning units. It is contemplated that suchunits can be fitted with suitable applicators such as various mix sprayguns of which units variously available under the following trade namesare non-limiting examples: GUSMER GX-7, GUSMER GX-7 400 series, GUSMERGX-125 or GUSMER GX-8, and GlasCraft Probler P2 impingement mix sprayguns. Where such devices are employed, it is contemplated that the tworespective components can be mixed under high pressure inside the spraygun for the coating/lining material system. The mixed material is thenapplied to the desired substrate via the spray gun.

It is contemplated that the applied material can be compounded in asuitable manner to achieve an essentially instantaneous set. It is alsoconsidered to be within the purview of this disclosure that the appliedmaterial may compounded in such a way as to facilitate or permitpost-curing operations to be performed on the dispensed material. It iscontemplated that any specific post-curing processes involving materialssuch as disclosed material will be optional in many or most situations.

The method also contemplates various pre-cure and/or pre-application andpost cure steps and processes. Non-limiting examples of suitablepre-cure and/or pre-application steps include various surfacepreparation operations. It is contemplated that the plural componentaliphatic sprayable polymeric system can be applied to any suitablyprepared surface. Non-limiting examples of the pre-application processesor steps include various cleaning operations. It is contemplated thatthe material can be successfully applied to surfaces that are reasonablyfree of surface dirt and contamination. The surface to which thematerial is applied can be difficult-to-coat surfaces of which DYNEEMAis but one example.

Additional examples of precure/preapplication steps include varioussurface preparation steps include, but are not limited to, priming andvarious surface treatments such as corona discharge treatment.

It is contemplated that the applied plural component polymeric systemachieves an initial cure essentially instantaneous with application. By“essentially instantaneous cure” as used herein, it is contemplated thatthe applied plural component aliphatic sprayable polymeric urea systemis stable without appreciable running or puddling upon application witha dry and tack free surface as defined in test method ASTM D 1640(Standard Test Methods for Drying, Curing, or Film Formation of OrganicCoatings at Room Temperature) achieved within three minutes ofapplication.

The plural component polymeric system material as disclosed herein maybe applied on any suitable substrate surface. In most situations, it iscontemplated that the system material can be successfully applied tosubstrate surfaces that are clean and free of dirt, oils, and otherdebris. It is contemplated that the target substrate can be cleaned andprepared by any suitable industrial cleaning method.

The polymeric coating material can be applied directly to the outersurface of the substrate. It is also contemplated that the substrate canbe treated with various substrate treatment processes including, but notlimited to, various passivation techniques, sealants, primers and thelike. It is contemplated that the polymeric coating material disclosedherein can be applied directly to the substrate surface and achieve thedesired level of adhesion. However, where desired or required, it isconsidered to be within the purview of this disclosure to interpose atleast one adhesion promoting material between the substrate and theapplied material.

Spray application can occur in a single pass or multi pass system withthe dispensed material applied to an ultimate or final thickness between25 mils and 80 mils in certain applications. The applied material willbe dry and tack free within 3 minutes of application, with tack freestatus occurring in many formulations in less and 60 seconds. Once thematerial is tack free, the coated substrate such as a helicopter floorpanel is considered suitable for continued assembly.

It has been found quite unexpectedly that polymeric material disclosedherein exhibits good adhesion to various difficult to coat materialssuch as UHMWPE and the like remains stable upon prolonged high trafficusage. It is also based upon the discovery that the applied coatingcomposition will not compromise that ballistic impedance of theassociated substrate when the construct is used as vehicle armor.

To further illustrate the present invention, the following examples aregiven. It is to be understood that these examples are provided forillustrative purposes and are not to be construed as limiting the scopeof the present invention.

Example I

A polymeric composition was prepared according to the present disclosurein the following manner. The following compounds in the stated weightpercentages were admixed to form the resin component:

TABLE-US-00001 TRADENAME QUANTITY PERCENT SOLIDS Polyetheramine D-200047.0 pbw 100 ETHACURE 100 19.0 pbw 100 Melamine 3.0 pbw 100 AluminumTrihydrate 5.0 pbw 100 Zinc borate 5.0 pbw 100 Bromine material 10.0 pbw100 (60% bromine) K-Flex 188 (for adhesion) 1.0 pbw 100 Pigment 10.0 pbw100

The resultant composition is a liquid material under ambient conditionsand has a viscosity suitable for spray application processes

The second component of the composition of the present inventioncomprises a liquid isocyanate composition comprised of 95 pbwINNOVATHANE and 5 pbw ANTIBLAZE 80/FRYOL PCF. The resulting material hasa viscosity under ambient conditions suitable for spray applicationprocesses. The estimated NCO is 15%.

Example II

A polymeric composition was prepared according to the present disclosurein the following manner. The following compounds in the stated weightpercentages were admixed to form the resin component:

TABLE-US-00002 TRADENAME QUANTITY PERCENT SOLIDS Polyetheramine D-200041.5 pbw 100 PLURACOL PEP 550 10.0 pbw 100 ETHACURE 100 15.5 pbw 100Melamine 4.0 pbw 100 Aluminum Trihydrate 5.0 pbw 100 Zinc borate 5.0 pbw100 SAYTEK 102E 10.0 pbw 100 K-Flex 188 (for adhesion) 1.0 pbw 100Pigment 8.0 pbw 100

The resultant composition is a liquid material under ambient conditionsand has a viscosity suitable for spray application processes.

The second component of the composition of the present inventioncomprises a liquid isocyanate composition comprised of 70 pbwINNOVATHANE, 25 pbw RUBINATE 9257 and 5 pbw ANTIBLAZE 80/FRYOL PCF. Theresulting material has a viscosity under ambient conditions suitable forspray application processes. The estimated NCO is 19%.

Example III

A polymeric composition was prepared according to the present disclosurein the following manner. The following compounds in the stated weightpercentages were admixed to form the resin component:

TABLE-US-00003 TRADENAME QUANTITY PERCENT SOLIDS Polyetheramine D-200045.0 pbw 100 PLURACOL PEP 550 7.5 pbw 100 ETHACURE 100 17.5 pbw 100Melamine 3.0 pbw 100 Aluminum Trihydrate 2.0 pbw 100 Zinc borate 6.0 pbw100 SAYTEK 102E 10.0 pbw 100 K-Flex 188 (for adhesion) 1.0 pbw 100Pigment 8.0 pbw 100

The resultant composition is a liquid material under ambient conditionsand has a viscosity suitable for spray application processes.

The second component of the composition of the present inventioncomprises a liquid isocyanate composition comprised of 85 pbwINNOVATHANE, 10 pbw RUBINATE 9257 and 5 pbw ANTIBLAZE 80/FRYOL PCF. Theresulting material has a viscosity under ambient conditions suitable forspray application processes. The estimated NCO is 16.7%.

Example IV

A polymeric composition was prepared according to the present disclosurein the following manner. The following compounds in the stated weightpercentages were admixed to form the resin component:

TABLE-US-00004 TRADENAME QUANTITY PERCENT SOLIDS Polyetheramine D-200038.0 pbw 100 PLURACOL PEP 550 7.0 pbw 100 ETHACURE 100 16.0 pbw 100Melamine 3.0 pbw 100 EXOLITE AP 423 15.0 pbw 100 Magnesium hydroxide 7.0pbw 100 SAYTEK 102E 3.0 pbw 100 K-Flex 188 (for adhesion) 1.0 pbw 100Pigment 8.0 pbw 100

The resultant composition is a liquid material under ambient conditionsand has a viscosity suitable for spray application processes.

The second component of the composition of the present inventioncomprises a liquid isocyanate composition comprised of 85 pbwINNOVATHANE, 10 pbw RUBINATE 9257 and 5 pbw ANTIBLAZE 80/FRYOL PCF. Theresulting material has a viscosity under ambient conditions suitable forspray application processes. The estimated NCO is 16.7%.

Example V

In order to apply the various compositions, the components outlined inExamples I through IV were processed using a GUSMER H-3500 pluralcomponent proportioning pump capable of capable of high temperature andhigh pressure at a 1:1 by volume ratio. The proportioning unit wasfitted with a GlasCraft P2 air purge spray gun fitted with an 01chamber/tip combination. The systems were processed at a spray pressureof 2200 psi fluid pressure and processing temperature of 150-160.degree. F.

Samples of Example I through IV were applied to a plastic film sheet forpreparation of free film samples for testing. The following results werenoted and are summarized in the following table.

TABLE-US-00005 ELASTOMERIC PROPERTIES EXAMPLE EXAMPLE EXAMPLE EXAMPLETEST METHOD III III IV GEL TIME, 3-5 2-4 3-5 3-5 secTack free, sec 10 1010 10 Shore D Hardness 50 62 55 96 ASTM D 2240 Tensile strength, 46502610 3670 2625 psi ASTM D 638, D412 Elongation, % 450 100 285 131 Tearstrength, pli 520 350 385 485 ASTM D624

Examples VI-X

Compositions are prepared according to the procedures and formulationspreviously outlined. The respective four polymeric material formulationsare applied in the manner previously designated to substrates of DYNEEMAsubstrate configured for use as antiballistic armor for high trafficfloor areas on helicopter floors. The respective formulations areapplied at a thickness of 100 microns and subjected to variousactivities including general wear and defensive actions and thus includescuffing, impact tests, chipping, scarring and the like. The appliedmaterials exhibit surprising resistance to some or all of chipping,denting, gouging abrasion and the like.

Examples X-XIV

Samples of the DYNEEMA armor material with one of the respectiveformulations applied at a thickness of 100 microns are tested todetermine the antiballistic characteristics of the associated construct.The constructs are tested for resistance to standard ballistic materialsaccording to conventional military specifications. Little or nodegradation in antiballistic characteristics is noted.

Examples XV-XIX

Compositions are prepared according to the procedures and formulationspreviously outlined with respect to Examples I-V. The respective fourpolymeric material formulations are applied in the manner previouslydesignated to substrates of DYNEEMA UD HB substrate material configuredfor use as antiballistic armor for high traffic floor areas onhelicopter floors. The respective formulations are applied at athickness of 100 microns and subjected to various activities includinggeneral wear and defensive actions and thus include scuffing, impacttests, chipping, scarring, and the like. The applied materials exhibitsurprising resistance to some or all of chipping, denting, gougingabrasion and the like. Samples of other substrates such as SPECTRA andTWARON are also tested and exhibit chip, dent, and gauge resistance.

Examples XX-XXIV

Samples of the DYNEEMA UD HB armor material with each of the respectiveformulations are applied at a thickness of 100 microns are tested todetermine the antiballistic characteristics of the associated construct.The constructs are tested for resistance to standard ballistic materialsaccording to conventional military specifications. Little or nodegradation in antiballistic characteristics is noted. Similar tests arerun with SPECTRA and TWARON with similar results.

Example XXV

The formulations outlined in Examples I through IV are modified in orderto integrate fungicide material Zinc pyrithane specifically materialcommercially available under the trade name ZINK OMADINE from ArchBiocides in amounts varying from 0.001 to 0.01 pbw. The material isintegrated in the resin or first component prior to integration withisocyanate component. The final formulations are prepared and applied asoutlined in Example V and exhibit performance characteristics of thenature outlined in that Example.

Example XXVI-XXXI

Samples prepared according to the process outlined in Examples I throughV as well as XXV are evaluated to various environmental challenges asoutlined in MIL-STD-810F.

1. High Temperature Storage (Cyclic) Test per Mil-STD-810F Method 501.4Procedure I Table 501.4-11.

Samples of 4″.times.4″ are exposed to seven 24 hour temperature/cyclesvariable between 38.degree. C. and 80.degree. C. The samples arevisually inspected at the end of the seventh cycle after being broughtback to ambient. No visible damage is noted.

2. Low Temperature Storage per Mil-STD-801 F Method 502.4, Procedure I.

Samples are stabilized at −60.degree. C. for a 72 hour period and thenreturned to ambient. No visible damage to the samples is noted uptonvisual inspection. Sample size is 4″.times.4″.

3. Hot/Cold Storage (Oversized Samples) per Mil-STD-801 F Method 502.4,501.4.

Samples with dimensions 47″.times.6″.times.1″ are exposed seven 24 hourcycles with temperature extremes of +30.degree. C. and +70.degree. C.and repeated with a temperature extreme of −50.degree. C. Samples arevisually inspected after return to ambient and exhibit no visibledamage.

4. Humidity Test Per Mil-STD-810 F Method 507.4 Paragraph 4.5.2.

Samples with dimensions of 4″.times.4″ are preconditioned+23.degree.C./50% RH for 24 hours and exposed to five 48 hour temperature humiditycycles varying between 50% RH and 95% RH with temperatures cyclicallyvarying between 30.degree. C. and 70.degree. C. Samples are returned toambient and evidence no damage upon visual inspection.

5. Transit Drop per Mil-STD-801 F Method 507.4 Paragraph 4.5.2. Samplesare 10″.times.10″.times.1″ and are exposed to 26 drops from 48″ on allcorners, edges and faces. Visual inspection indicates durable material.Minor corner splitting in certain samples is within tolerances.

6. Contamination by Fluids (Immersion) Mil-STD-801 F Method 504

Thirty six samples measuring 4″.times.4″ are prepared for eachformulation according to the methods outlined in Examples I-V and XXV.Samples were immersed in various test fluids including jet fuel, saltwater, hydraulic fluid and lubricating oil with fuels and salt watermaintained at ambient while hydraulic fluid and oil are held at 70degrees C. with a daily cycle of 8 hrs wetted and 16 hours draining for30 days. Samples are visually inspected and evidenced no damage. Onesample is removed and inspected every 5 days. Sample evidence no minimaldegradation upon visual inspection.

7 Adhesion Test per Mil-PRF-85285 Paragraph 4.5.5

Samples are exposed to a 24 hour soak in deionized water and removedfrom the immersion. Sample sizes are 10″.times.10 and 12″.times.4″Within 3 minutes of removal two parallel scribes are made of 2″ that are¾″ apart. The material is then scribed from opposite ends to form an Xpattern. A 1 inch wide strip of tape is placed across the scribes. Aroller as specified in FED STD141 is passed 8 times over the tape. Thetape is removed in one quick motion and visually examined. Minor flakingmay be noted in some samples at the scribe line but is withintolerances.

8. Adhesion Test per Mil-PRF-23377 Paragraph 4.5.4

Samples are exposed to a 24 hour soak in deionized water and removedfrom the immersion. Sample sizes are 10″.times.10 and 12″.times.4″Within 3 minutes of removal two parallel scribes are made of 2″ that are¾″ apart. The material is then scribed from opposite ends to form an Xpattern. A 1 inch wide strip of tape is placed across the scribes. Aroller as specified in FED STD141 is passed 8 times over the tape. Thetape is removed in one quick motion and visually examined. Minor flakingmay be noted in some samples at the scribe line but is withintolerances.

9. Adhesion Test per Mil-PRF-46103E Paragraph 4.4.9

Samples measuring 12″.times.4″ and 10″.times.10″ are prepared. Four inchlong parallel cuts are made on the sample followed by a 1″ cut at aright angle so that a tab can be peeled from the sample. A two poundweight is attached to the tab so that the resultant peel force is normalto the plane of the sample. Gage marks are made on the sample formeasurement for measurement of peeling. The weight is permitted to standfor four hours at ambient temperatures. No additional peeling isevidenced in the samples.

The pale member 10 can be configured with suitable through bores andapertures as desired or required to accommodate various vehicularfittings, structural ambers and the like. As depicted in FIG. 7A, thepanel 10 has suitable apertures 90. These apertures may be produced bysuitable processes including but not limited to cutting milling or thelike. Where desired or required the interior surface of the through borecan be coated with the coating material layer 14 to encase and reinforcethe aperture surface.

In situations where greater reinforcement is desired, the aperture(s)can be fitted with suitable guards 92. One embodiment of such rivetguards 92 is depicted in FIG. 7B. The rivet guard may be configured as amating two piece member with a suitable flange element configured torest on the respective opposed surfaces of the panel member 12. Wheredesired or required the inner channel surface defined in the rivet guardcan be threaded to receive appropriate mating external attachmentdevices (not shown).

The two pieces of the rivet guard can be joined by any suitable mannersuch as mating threaded surfaces. The rivet guards can overlay thevarious coating layers in certain embodiments. However the insertion ofrivet interposed between the coating layer and the panel member iscontemplated in some embodiments.

While the invention has been described in connection with what ispresently considered to be the most practical and preferred embodiment,it is to be understood that the invention is not to be limited to thedisclosed embodiments but, on the contrary, is intended to cover variousmodifications and equivalent arrangements included within the spirit andscope of the appended claims, which scope is to be accorded the broadestinterpretation so as to encompass all such modifications and equivalentstructures as is permitted under the law.

What is claimed is:
 1. A composite article comprising: a polymericsubstrate composed of fibers of at least one of ultrahigh molecularweight polyethylene and aramid in a polymeric matrix, the polymericsubstrate having at least one face, the polymeric substrate having asurface energy less than 30 dyne; a coating layer in overlying adheredrelationship with the at least one face of the polymeric substrate, thecoating layer composed of composition comprising a reactive blend of atleast one first component and at least one second component, wherein thefirst component is consists essentially of a polymer and/or a blend ofpolymers present in an amount sufficient to impart a predeterminedamount of tensile strength, hardness, flexibility and adhesive strengthto the resulting polymeric coating and the second component is anisocyanate or isocyanate quasi-prepolymer; and a substrate panel capoverlying at least one side edge of the substrate panel, the substratepanel cap interposed between the coating layer and the substrate, thepanel cap having an elongated central body and a pair of wall membersextending contiguously from opposed edges of the central body, the wallmembers connected to regions of the respective first and second facesproximate to the side edge.
 2. The composite device of claim 1 whereinthe first component of the coating composition is composed of at leastone of amine-terminated polyetherpolyols, amine-based tetrol polyols andhigh functional polyols wherein at least one of difunctionalamine-terminated polyether polyols has a molecular weight between 400and 4000, tetrafunctional polyols of alkylene oxide or pentafunctionalpolyols of alkylene oxide has a molecular weight in the range of 400 to600 and wherein the second component is an isocyanate component composedof at least one of an aromatic isocyanate and a quasi prepolymer ofisocyante having a percent NCO between about 15 and
 25. 3. The compositedevice of claim 2 wherein the coating composition encases the polymericsubstrate.
 4. The composite device of claim 2 wherein the coatingcomposition is directly adhered to the substrate.
 5. A vehicle having atleast one interior surface, the interior surface composed of a least onepolymeric panel, the polymeric panel having: a polymeric substrate panelcomposed of fibers of at least one of ultrahigh molecular weightpolyethylene and aramid in a polymeric matrix, the polymeric substratehaving at least one face and a surface energy of less than 30 dyne; acoating layer in overlying adhered relationship with the at least oneface of the polymeric substrate, the coating layer composed ofcomposition comprising a reactive blend of at least one first componentand at least one second component, wherein the first component isconsists essentially of a polymer and/or a blend of polymers present inan amount sufficient to impart a predetermined amount of tensilestrength, hardness, flexibility and adhesive strength to the resultingpolymeric coating and the second component is an isocyanate orisocyanate quasi-prepolymer; wherein the polymeric panel has an inwardlyfacing surface that is resistant to at least one of chipping, gaugingand abrasion.
 6. The vehicle of claim 5 wherein the polymeric panel ispositioned on an interior surface and the vehicle is one of ahelicopter, airplane, or an automotive vehicle.
 7. The vehicle of claim6 wherein the polymeric panel includes at least one of: a substratepanel cap overlying at least one side edge of the substrate panel, thesubstrate panel cap having an elongated central body and a pair of wallmembers extending contiguously from opposed edges of the central body,the wall members connected to regions of the respective first and secondfaces proximate to the side edge; at least one kick guard, the kickguard attached to at least one face of the substrate panel in overlyingrelationship wherein the coating composition is interposed between thekick guard and the substrate; at least one fiber reinforced laminatelayer adhered to at least one face of the substrate panel; a deformablelayer composed of polymeric foam attached to a second face of thesubstrate panel.